Film Transfer Sheet Peelable Layer Design

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Solution Overview

Problem

Conventional thermal transfer methods face challenges in achieving durable images due to lack of abrasion and chemical resistance, and issues with peeling failures in intermediate transfer recording media.

Innovation Solution

A film transfer sheet and intermediate transfer recording medium are developed with a peelable transparent sheet and a resin layer having a pressure-sensitive adhesive with a specific storage elastic modulus, ensuring excellent peelability and durability by transferring the adhesive layer to a receiving member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protective layer thermal transfer sheet is used to transfer a protective layer onto a thermal transfer image, then the image durability is improved, but the protective layer thickness is limited to several microns which cannot provide strong abrasion resistance

Engineering Contradiction:

Improveimage durabilityVSAvoidprotective layer thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The protective layer is segmented into two parts: a thin functional protective layer (several microns) transferred by thermal transfer for chemical resistance, and a thick mechanical protective layer (hundreds of microns) applied separately for abrasion resistance. This segmentation allows each layer to optimize its thickness for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A primer layer serves as an intermediary between the thermal transfer image and the thick protective coating. The primer layer provides adhesion promotion and surface preparation, enabling the thick protective coating to bond effectively to the delicate thermal transfer image without causing damage during application.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If an intermediate transfer recording medium is used to transfer an image to an optional subject, then the adaptability is improved, but peeling failures occur due to inadequate peelability

Engineering Contradiction:

Improvetransfer to optional subjectsVSAvoidpeeling performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The peelability of the intermediate transfer recording medium is optimized by adjusting parameters of the resin layer including storage elastic modulus (10^5 to 10^6 Pa at 130-150°C), glass transition temperature (-50°C to 0°C), and composition ratios. These parameter changes enable reliable peeling across different transfer-receiving members while maintaining image quality.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the resin layer has high adhesion strength to prevent peeling failures, then the peelability is improved, but cohesive failure occurs within the resin layer itself

Engineering Contradiction:

ImprovepeelabilityVSAvoidcohesive strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The resin layer is designed with different local properties: higher adhesion strength at the interface with the support film for stable handling, and optimized cohesive strength throughout the bulk for uniform peeling. The composition gradient and thickness optimization (3-10 microns) create local quality variations that prevent both peeling failures and cohesive failures.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides enhanced durability and peelability, preventing cohesive failure and ensuring stable transfer, while the peelable transparent sheet functions as a strong protective layer, improving the image's resistance to friction and chemicals.

Implementation Method 1

a resin layer and a peelable transparent sheet provided with an adhesive layer, in which a sheet substrate and the peelable transparent sheet are laminated together

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a thermal transfer sheet having a dye layer is heated imagewise from the back face thereof by using a thermal head or the like

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a sublimation transfer type and a heat melting transfer type

Methodology Applied

Scientific EffectSublimation: Sublimation

Implementation Method 4

a sublimation transfer type and a heat melting transfer type

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS8450241B2Film transfer sheet and intermediate transfer recording medium

Publication Date: 2013.05.28 DAI NIPPON PRINTING CO LTD

AI summary

A film transfer sheet including a sheet substrate provided with a layer via a resin layer and a peelable transparent sheet provided with an adhesive layer. The sheet substrate and the peelable transparent sheet are laminated together such that the layer is overlapped on the peelable transparent sheet and peeling is designed to occur between the layer and the peelable transparent sheet so as to transfer the peelable transparent sheet provided with the adhesive layer to a transfer-receiving member. The resin layer includes as an essential component a pressure-sensitive adhesive having a storage elastic modulus of 3.0 ×105 Pa to 1.2 ×106 Pa at a temperature of 130° C. to 150° C. Also provided is an intermediate transfer recording medium including a sheet substrate provided with a layer via resin layer and a peelable transparent sheet provided with a dye receptive layer, in which the sheet substrate and the peelable transparent sheet are laminated together.